Print quality setup using banks in parallel

ABSTRACT

The present invention embraces a method and apparatus for an efficient and economical print quality setup for thermal printers. A thermal printhead of a thermal printer constitutes multiple printhead banks. The printhead banks may be controlled by strobe signals. While configuring print quality, each of the strobe signals may operate separately with different power causing the printhead banks to operate in different configurations while printing an identical pattern. As each the banks are operating in different configuration, they each print the identical pattern with a different print quality. One print quality may be selected from the different quality patterns printed by each printhead bank on a single printed label or media. The selected quality pattern corresponds to a quality factor. The method may reduce the time to select a configuration and may reduce the amount of usage of media or labels.

FIELD OF THE INVENTION

The present invention relates to improvements in printers, and moreparticularly, to improvements in the print quality setup of a thermalprinter.

BACKGROUND

Generally speaking the print quality setup of a thermal printer may bedifficult, time consuming and may waste expensive labels. One typicalapproach of determining the print quality setup includes printing labelswith different settings and allowing the user to manually select thebest label. This procedure may waste many labels and is very undesirableespecially if the labels are expensive. Another approach entailsanalyzing the media (paper and ribbon) and determining the compositionof the printed label. This approach adds the expense of an analyzer andassociated software to the system. In yet another approach, anelectronic or visual ID is positioned on the media and the print qualitysetup is based predetermined settings. This approach may requirevalidation of all possible media to be used on the printer and would notsupport unknown media.

Therefore, a need exists for an efficient and inexpensive solution forthe print quality setup of thermal printers.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method andapparatus for an efficient and economical print quality setup forthermal printers. A thermal printhead of a thermal printer constitutesmultiple printhead banks. The printhead banks are controlled by strobesignals.

In an exemplary embodiment, a printer may comprise a set of printheadbanks, wherein each of the set of printhead banks is operable toindependently print an identical pattern with a different print qualityon a media; a processor capable of generating a strobe signal for eachof the set of printhead banks based on a quality factor, wherein thequality factor determines the print quality for each of the identicalpatterns on the media, wherein the processor selects the quality factorbased on a user selection of a preferred pattern; and the mediacomprising a set of the identical patterns, each with different printquality, each printed by a different printhead bank. The processor sendsa corresponding strobe signal and data signal to a correspondingprinthead bank of the set of printhead banks. The placement of theprinter in a normal print mode of operation causes the set of printheadbanks to print media based on the quality factor corresponding to thepreferred pattern selection.

An algorithm of the processor may analyze the selected preferred patternand determines whether to tune” the quality factor associated with thepreferred pattern. If the algorithm of the processor decides to tune thequality factor associated with the preferred pattern, the processorgenerates another set of quality factors based on the preferred patternselection as a seed. The processor then proceeds to select same oranother preferred pattern based on the another set of quality factors.The preferred pattern selection is aided or automated by a scanner andprocessor software. The processor may independently control the qualityfactor associated with each strobe signal.

In another exemplary embodiment, a method for printing may comprise thesteps of: receiving, by a processor of a printer, a prompt from a userto start a print quality factor setup including a generation of a set ofN quality factors, wherein a quality factor determines a print qualityof a pattern of a media; generating, by the processor of the printer, aset of N strobe signals corresponding to the set of N quality factors;and transmitting, by the processor of the printer, each of the set ofthe N strobe signals and each of an associated set of N data signals toeach of a corresponding set of N printhead banks. Each of the Nprinthead banks print a specific pattern and collectively print Npatterns on the media. The user reviews the N patterns on the media andselects a preferred pattern based on the print quality.

In another aspect, the present invention embraces a strobe signal thatmay comprise sequence of variable length pulses that controls an amountof energy applied to resistive elements of printhead of the printer.Also, the processor of the printer may determine whether to tune thequality factor based on an analysis of the quality factor of theselected preferred pattern.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary embodiment of a system that provides anefficient print quality setup.

FIG. 2 illustrates an exemplary flowchart for a method that provides anefficient print quality setup.

FIG. 3 illustrates an exemplary image of label comprising four separatepatterns.

DETAILED DESCRIPTION

The present invention embraces a method and apparatus for an efficientand economical print quality setup for thermal printers. A thermalprinthead of a thermal printer constitutes multiple printhead banks. Theprinthead banks are controlled by strobe signals. In a print qualitysetup operation, the strobe lines from all the banks may be combined andapplied with one power signal resulting in a constant print qualitythroughout all of the printhead banks. This means that all of theprinthead banks may be printing with the same print quality. Duringprint quality setup, excessive labels must be printed to select thepreferred print quality. As used herein, “strobe signals” aretransmitted on the “strobe line”. As used herein, a “label” is a type of“media”.

For the present invention, while configuring print quality, all thestrobe lines may operate separately with different power signals causingthe printhead banks to operate in different configurations. As all thebanks are operating in different configurations, one print quality maybe selected from the given options or patterns printed by each printheadbank on a single printed label. The selected pattern corresponds to aquality factor. The method may reduce the time to select a configurationand may reduce the amount of usage of labels.

Further, the selected configuration, based on a specific quality factor,may be loaded to the connected strobe lines for normal printingoperation. In other words, the method and apparatus for print qualitysetup may be based on independently controlling the strobe signals forthe printhead banks to produce the printing of a different print qualityfrom each bank. Then, selecting a preferred print quality pattern andloading the corresponding quality factor to a connected strobe line fornormal print operation. In the present invention, the print qualitysetup is based on quality factors and may be referred to as a printquality factor setup.

FIG. 1 illustrates an exemplary embodiment of a system 100 for providingan efficient print quality setup that results in achieving a high printquality without printing excessive labels. System 100 may compriseprinter 102 and scanner 104 (optional). System 100 is operated by user101. Printer 102 comprises processor 106, printhead banks 108 and label110. Printhead banks 108 may comprise N banks including bank1 121, bank2122, bank3 123, bank4 124, . . . bankN 125. Label 110 may comprise Ndata patterns including pattern_A 141, pattern_B 142, pattern_C 143,pattern_D 144, . . . pattern_Nth 145. In operation, processor 106 mayreceive a prompt from user 101 to start a setup of quality factors. Thequality factors represent a print quality specification.

In response to receiving the prompt, processor 106 may generate andtransmit N data patterns and N strobe signals to the printhead banks108. The N strobe signals may comprise strobe1 111, strobe2 112, strobe3113, strobe4 114, . . . strobeN 115. The N data patterns may comprisedata1 116, data2 117, data3 118, data4 119, . . . dataN 120. Each of theN data patterns and N strobe signals may be coupled to a correspondingone of the printhead banks 108. That is, strobe1 111 may be coupled tobank1 121, strobe2 may be coupled to bank2 122, etc.

Each of the N strobe signals define a quality factor corresponding to apattern that may be printed on label 110. The strobe signal may comprisea sequence of variable length pulses, typically a sequence from 1 to 6pulses per single dot line. The duration of pulses may be from 10's ofmicroseconds to 100's of microseconds. This pulse specification maycontrol the amount of energy going into resistive elements (dots) of theprinthead, thus variably heating up the elements causing thermal paperto react or ribbon to melt.

Dot line is a single line of dots produced by the printhead on thepaper. Printing involves producing multiple dot lines sequentially tocreate an image as the paper moves forward.

Returning the FIG. 1, each bank in the printhead banks 108 receives aquality factor via a strobe signal that results in a correspondingpattern to be printed on a label. For example, bank1 121 receives aquality factor via strobe1 111. Based on this quality factor, bank1 121generates a heat profile print_A 131 that results in pattern_A 141 beingprinted as a part of label 110. Likewise, bank2 122 receives anotherquality factor from strobe2 112. Based on this another quality factor,bank2 122 generates a heat profile print_B 132 that results in pattern_B142 being printed as a part of label 110. BankN 125 receives yet anotherquality factor from strobeN 115. Based on this yet another qualityfactor, bankN 125 generates a heat profile print_Nth 135 that results inpattern_N 145 being printed as a part of label 110. The remaining banks,illustrated in FIG. 1, have corresponding heat profiles Print_C 133 andPrint_D 134. Label 110 comprises N patterns, each reflecting a differentquality factor as specified by each of the N strobe signals. Each of theset of printhead banks 108 independently prints an identical pattern ona label.

Once label 110 is printed, a user 101 may review the patterns on label110 and select a preferred pattern. The preferred pattern corresponds toa specific quality factor. For example, the preferred pattern may bepattern_B 142. After making this selection, user 101 may proceed withconventional printing based on the preferred pattern, pattern_B 142. Or,in a second cycle, a printer processor algorithm may determine iffurther tuning of the quality factors is necessary. Processor 106 maytune the selection and proceed to generate another set patterns based onthe quality factor of the preferred pattern as a seed, e.g., pattern_B142. This another set of patterns that are printed on label 110 wouldresult in the printing the following set of patterns: pattern_B1,pattern_B2, pattern_B3, etc. (these patterns are not shown on FIG. 1).User 101 may select a preferred pattern from the second cycle set ofpatterns, e.g., pattern_B3, and proceed with conventional printing. Or,the user may proceed with a third cycle of tuning, and generate yetanother label 110 based on pattern_B3. The action may result in a set ofpatterns, pattern_B31, pattern-B32, pattern_B34, etc. (These patternsare not shown on FIG. 1). As in prior cycles, once label 110 is printed,a user 101 may review the patterns on label 110 and select same oranother preferred pattern. After making this selection, user 101 mayproceed with conventional printing based on the preferred pattern, orthe user may proceed with yet another cycle of tuning or “fine tuning”.For each cycle of “fine tuning”, the user repeats the steps of executingprint quality setup and prints another multi-pattern label for reviewand re-selection of a preferred pattern. This procedure can furtherimprove the print quality of the label 110.

In summary, processor 106 independently controls the bank strobe signals(transmitted on the strobe lines) to allow the printhead banks 108 toprint a different print quality at each bank. FIG. 3 illustrates anexemplary image of a label comprising four separate patterns, i.e., amulti-pattern label.

N is a number having a value of at least 2. The previous describeprocedure may have M cycles of tuning or “fine tuning”. Without theutilization of independent strobe control for each bank, the printquality factor setup may require up to N times as many labels and Ntimes as much time to achieve the same result. So, for j patterns of“fine turning”, the procedure may save j*(N−1) labels.

As an alternative to user 101 independently selecting the preferredpattern, a scanner may scan label 110 and provide the scan of label 110to processor 106. With printer processor algorithms, processor 106 mayanalyze the scan of label 110 and aids or automates the user in theselection of a preferred pattern. Based on either a decision from user101 or a decision by processor 106, processor 106 proceeds toconventional printing of the preferred pattern, or proceeds to a cycleof “fine tuning” based on the preferred pattern as the seed.

FIG. 2 illustrates an exemplary flowchart 200 for a method that providesan efficient print quality setup to achieve a high print quality withoutprinting excessive media or labels. The method may comprise thefollowing steps:

User prompts printer to start a print quality factor setup and generatea set of N quality factors. (step 202)

Based on the set of N quality factors, a processor of the printergenerates a set of N strobe signals corresponding to the set of Nquality factors. (step 204)

Based on the set of N strobe signals, the processor transmits each ofthe N strobe signals to a corresponding set of N printhead bankstogether with data corresponding to a pattern for each portion of amedia or label. (step 206)

Each of the N printhead banks prints a portion of a media or labelcontrolled by one of the N quality factors. (step 208)

Does the user independently review N printed patterns on the media orlabel and select a preferred pattern? If yes, the user selects apreferred pattern. (step 210)

If no, a scanner and processor software analyze N printed patterns andaids or automates the user in the selection of a preferred pattern.(step 212)

With the preferred pattern selection, does an algorithm in printerprocessor determine if further fine tuning of the quality factors isnecessary? (step 214)

If no, the printer is setup for a quality factor corresponding to thepreferred pattern selection. (step 218)

If yes, the processor of the printer generates another set of N qualityfactors based on the preferred pattern selection as a seed. (step 216)

The method then repeats step 206 and cycles to select another preferredpattern.

FIG. 3 illustrates an exemplary image of label 300 comprising fourseparate patterns, i.e., a multi-pattern label. Label 300 is printedbased on step 208 of FIG. 2. Label 300 comprises Pattern_A—141 which wasprinted by Bank1—121, Pattern_B—142 which was printed by Bank2—122,Pattern_C—143 which was printed by Bank3—123, and Pattern_D—144 whichwas printed by Bank4—124.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

1. A printer, comprising: a set of printhead banks, wherein each of theset of printhead banks is operable to independently print an identicalpattern with a different print quality on a media; a processor operableto generate a strobe signal for each of the set of printhead banks basedon a quality factor, wherein the quality factor determines the printquality for each of the identical patterns on the media, wherein theprocessor selects the quality factor based on a user selection of apreferred pattern; and the media comprising a set of the identicalpatterns, each with different print quality, each printed by a differentprinthead bank, wherein, the processor sends a corresponding strobesignal and data signal to a corresponding printhead bank of the set ofprinthead banks.
 2. The printer according to claim 1, wherein aplacement of the printer in a normal print mode of operation causes theset of printhead banks to print media based on the quality factorcorresponding to the preferred pattern selection.
 3. The printeraccording to claim 1, wherein an algorithm of the processor analyzes theselected preferred pattern and determines whether to tune the qualityfactor associated with the preferred pattern.
 4. The printer accordingto claim 3, wherein, if the algorithm of the processor decides to tunethe quality factor associated with the preferred pattern, the processorgenerates another set of quality factors based on the preferred patternselection as a seed.
 5. The printer according to claim 4, wherein theprocessor then proceeds to select same or another preferred patternbased on the another set of quality factors.
 6. The printer according toclaim 1, wherein the preferred pattern selection is aided or automatedby a scanner and processor software.
 7. The printer according to claim1, wherein the processor independently controls the quality factorassociated with each strobe signal.
 8. A method, comprising the stepsof: receiving, by a processor of a printer, a prompt from a user tostart a print quality factor setup including a generation of a set of Nquality factors, wherein a quality factor determines a print quality ofa pattern of a media; generating, by the processor of the printer, a setof N strobe signals corresponding to the set of N quality factors; andtransmitting, by the processor of the printer, each of the set of the Nstrobe signals and each of an associated set of N data signals to eachof a corresponding set of N printhead banks, wherein each of the Nprinthead banks print a specific pattern and collectively print Npatterns on the media, and wherein the user reviews the N patterns onthe media and selects a preferred pattern based on the print quality. 9.The method according to claim 8, wherein the user places the printer ina normal printing mode causing the set of N printhead banks to print themedia based on the quality factor corresponding to the selectedpreferred pattern.
 10. The method according to claim 8, comprisingdetermining, by the processor of the printer, whether to tune thequality factor based on an analysis of the quality factor of theselected preferred pattern.
 11. The method according to claim 10,comprising, if the processor decides to tune the quality factor of theselected preferred pattern, generating, by the processor of the printer,another set of N quality factors based on the selected preferred patternas a seed.
 12. The method according to claim 11, comprising selecting,by the processor of the printer, same or another preferred pattern basedon the another set of N quality factors.
 13. The method according toclaim 8, wherein the preferred pattern selection by the user is aided orautomated by a scanner and processor software.
 14. The method accordingto claim 8, wherein, the processor independently controls the qualityfactor associated with each strobe signal.
 15. A method, comprises thesteps of: receiving, by a printer, a prompt from a user to start a printquality factor setup including a generation of a set of N qualityfactors, wherein a quality factor determines a print quality of apattern of a media; generating, by the printer, a set of N strobesignals corresponding to the set of N quality factors; processing, bythe printer, each of the set of N strobe signals and each of anassociated set of N data signals to generate a corresponding set of Nheat profiles; and printing, by the printer, a set of N patterns on themedia based on the corresponding set of N heat profiles, wherein, theuser reviews the set of N patterns on the media and selects a preferredpattern based on the print quality.
 16. The method according to claim15, comprising determining, by the printer, whether to tune the qualityfactor based on an analysis of the quality factor of the selectedpreferred pattern.
 17. The method according to claim 15, comprising, ifthe printer decides to tune the quality factor of the selected preferredpattern, generating, by the printer, another set of N quality factorsbased on the selected preferred pattern as a seed.
 18. The methodaccording to claim 17, comprising selecting, by the printer, a same oranother preferred pattern based on the another set of N quality factors.19. The method according to claim 15, wherein a strobe signal comprisessequence of variable length pulses that controls an amount of energyapplied to resistive elements of printhead of the printer.
 20. Themethod according to claim 15, wherein the printer independently controlsthe quality factor associated with each strobe signal.